Ramsey RPH-40000 User Manual

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Page 1

OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL RPH-40,000

INDUSTRIAL PLANETARY WINCH

WITH AIR TENSIONER AND 2 SPEED MOTOR

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF WINCH. SEE WARNINGS!

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TABLE OF CONTENTS

INTRODUCTION............................................................................................................... 1

WARRANTY INFORMATION ........................................................................................... 1

SPECIFICATIONS ............................................................................................................ 1

WARNINGS ...................................................................................................................... 1

HYDRAULIC SYSTEM REQUIREMENTS........................................................................ 2

PERFORMANCE CHARTS .............................................................................................. 2

WINCH OPERATION........................................................................................................ 3

CLUTCH OPERATION ..................................................................................................... 3

CABLE INSTALLATION.................................................................................................... 3

MAINTENANCE ................................................................................................................4

TROUBLE SHOOTING GUIDE......................................................................................... 4

INSTRUCTIONS FOR OVERHAUL ............................................................................. 5-12

MOUNTING CONFIGURATIONS ................................................................................... 12

DIMENSIONAL DRAWING ............................................................................................. 14

PARTS LIST AND PART DRAWING .........................................................................15-17

LIMITED WARRANTY ...................................................................................... Back cover

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…

RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 40,000

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully read and understand the "WARNINGS" and "OPERATION" sections of this manual.

WARRANTY INFORMATION

Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have any problems with our winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.

SPECIFICATIONS* (LOW SPEED MODE)

Rated Line Pull (lbs.) 40,000

(Kg.) 18,100

Gear Reduction 51.35:1

Weight (without cable)

LAYER OF CABLE *Rated line pull

per layer

*Cable Capacity

*Line Speed (at 17 GPM)

* These specifications are based on recommended wire rope of .75 inch dia. extra improved plow steel or equivalent

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

…………………………………………………………

lbs. 40,000 33,500 28,800 25,300 22,500 20,300 Kg. 18,100 15,100 13,000 11,400 10,200 9,200 ft. 25 55 95 135 185 235

m 7 1628415671 FPM 1618.721242729 MPM 4.8 5.6 6.3 7.2 8.2 8.8

…………………………………………………… ……………………………………………………

…………………………………………

123456

700 lbs. (318 Kg)

WARNINGS:

CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION. DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH. DO NOT DISENGAGE CLUTCH UNDER LOAD. STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS. STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE. DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE. DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PEOPLE. A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.

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HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts to properly match your hydraulic system to RPH-40000 winch performance. The charts consist of:

(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) Line speed (FPM) first layer vs. flow (GPM).

Performance is based on a motor displacement of 9.6 cubic inches with 17 GPM maximum flow rate. See page 13 for motor port size.

TYPICAL LAYOUT

DUAL-A & B PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

MOTOR

BRAKE

PORT

PUMP

PERFORMANCE CHARTS

(BASED ON 9.6 CU. IN./REV MOTOR)

40000

35000

30000

25000

CONTROL VALVE

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

20000

LINE PULL (Lbs.)

15000

10000

DELTA P @ MOTOR (PSI)

LINE SPEED (Ft/Min)

2500200015001000500

2800

FLOW (GPM)

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WINCH OPERATION

Before operating the winch for the first time, remove the cover from the breather vent at the back of the air

cylinder and the relief fitting on top of the clutch housing.

The best way to get acquainted with how your winch operates is to make test runs before you use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Learn to recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain confidence in operating your winch and its use will become second nature with you.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end of drum. If this happens, reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the cable.

CLUTCH OPERATION

To engage clutch:

1. Move the clutch control valve to the “clutch engaged” position.

2. Anytime the temperature is below freezing, run the motor in the “cable out” direction only until the drum starts to turn. In extreme cold temperatures (below 0o F/-18o C), pull out on the cable by hand only until

the drum starts to turn.

3. Wait at least 3 seconds for the clutch to fully engage, after which the winch is ready to winch in the cable.

WARNING: Do not attempt to engage the clutch by first running the winch motor and then moving the clutch control valve to the "clutch-engaged" position while the motor is running. Do not start picking up the load at the same time the clutch is being engaged.

To disengage clutch:

1. Run the winch in the "cable out" direction until the load is off the cable.

2. Move the clutch control valve to the "clutch-disengaged" position.

3. The cable may now be pulled off by hand.

CABLE INSTALLATION

Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope, opposite

hook, with plastic or similar tape to prevent fraying.

2. Insert the end of cable, opposite hook end, into the hole in drum barrel. Secure cable to drum barrel, using

setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.

3. Carefully run the winch in the “reel-in” direction. Keeping tension on end of cable, spool all the cable onto

the cable drum, taking care to form neatly wrapped layers.

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MAINTENANCE

Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of repair.

A. WEEKLY

1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and repair.

Check the pressure relief plug in top of the gear housing. Be sure that it is not plugged.

Lubricate cable with light oil.

B. MONTHLY

1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are

loose. Use grade 5 or better bolts.

2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.

C. ANNUALLY

1. Drain the oil from the winch annually or more often if winch is used frequently.

2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load in the

reel in direction. Drain the kerosene from the winch.

3. Refill the winch to the oil level plug with all-purpose SAE 80W-140 gear oil.

4. Inspect frame and surrounding structure for cracks or deformation.

TROUBLESHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH

1. Seals damaged or worn.

2. Too much oil. 2. Drain excess oil. Refer to OPERATION.

1. Replace seal.

3. Damaged gaskets. 3. Replace gaskets.

1. Low flow rate 1. Check flow rate. Refer to HYDRAULIC

WINCH RUNS TOO SLOW

2. Hydraulic motor

SYSTEMS performance chart page 2.

2. Replace motor.

worn out.

CABLE DRUM WILL NOT FREESPOOL

1. Clutch not disengaged

1. Check air pressure to clutch cylinder: 100 PSI Minimum required. Refer to page 13 for port location.

BRAKE WLL NOT RELEASE

1. Brake line disconnected or blocked.

1. Check brake function. Refer to page 12.

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INSTRUCTIONS FOR OVERHAUL

DIS-ASSEMBLY

1. Drain oil from gear housing #10 by removing pipe cap #44 from pipe nipple in end bearing. Remove reducer #43 and relief fitting #39. If new air cylinder is required, remove air cylinder #35 from cover by removing (4) capscrews #24.

Remove washer #26, nut #27, setscrew #22, and insert #32 from end of air cylinder rod. Apply

Loctite to threads of nut #27 and thread onto setscrew #22 to 3/8” from drive end, as shown below. Apply Loctite to threads of setscrew and thread insert #32 over end of setscrew and against nut. Use setscrew and nut to thread insert #31 into end of air cylinder rod. Tighten nut against cylinder rod, keeping 3/8” distance from drive end of setscrew to nut. If breather vent #40 is damaged, remove and replace.

AIR CYLINDER ROD

3/8

2. Disconnect tube #48 from elbow #33 on valve #49 and fitting #34 on bottom of brake #36. Remove motor #41 and gasket #36a by removing (2) capscrews #21. Remove valve #49, if needed, from motor by loosening (4) capscrews #16.

APPLY LOC-TITE TO SETSCREW

36a

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3. Remove brake assembly screws #18 from brake #36a to access (2) mounting screws #20

attaching brake to end bearing #9. Caution: Brake is spring loaded by clutch spring and must be restrained against end bearing as mounting screws are removed. Remove coupling #8 and gasket #36e from end bearing. Take note of mounting configuration for proper mounting of parts during re-assembly.

36c

36e

36d

36a

36e

4. Remove winch from tie bars #2 and #3 by removing (8) capscrews #19, (8) lockwashers #25, and

(4) shoulder bolts #29. Pull motor end bearing #9 from drum assembly #1.

OUTER-MOST

CAPSCREW

INNER-MOST CAPSCREWS

OUTER-MOST

CAPSCREW

Page 9

5. Pull drum assembly #1 upward from end bearing #10. Remove quad-rings #42 from grooves in

drum bushings. Remove input shaft #12, clutch springs #46 & #47 and washers #28 & #30 from end bearing. Examine splined ends of input shaft for signs of wear, replace if damaged.

Examine drum assembly #1 for signs of wear. If splines inside of drum driver (332148) are damaged, drum driver must be replaced. Remove drum driver by unscrewing (8) capscrews (414978). If bushings show signs of wear, replace by pressing old bushings from drum and removing o-rings from grooves in drum and drum driver. Place well-oiled o-rings (462043) into grooves in drum and drum driver. Press new bushing (412078) into end of drum opposite drum driver and press bushing (412079) into drum driver until flange of bushings are flush against drum and driver.

O-RING 462043

DRUM DRIVER GROOVE

BUSHING 412079

O-RING

462043

BUSHING

412078

DRUM BUSHING

ASSEMBLY

Page 10

6. Remove output coupling #6 and coupling shaft #7 from end

bearing #10. Examine bearings #14 pressed in output coupling for signs of wear. Replace bearings, if necessary, by pressing old bearings from coupling and press new bearings into each end of output coupling. Place coupling shaft into bearings.

7. Remove (12) capscrews #17 to pull gear-housing cover #4

and gasket #37 from ring gear #51. Remove input thrust washer, sun gear and carrier assemblies from inside of ring gear. Remove ring gear #51 and gasket #37 from end bearing #10. Examine shifter shaft #13 for signs of wear, replace if necessary. Examine bushing #15 for signs of wear. Replace bushing, if necessary, by pressing old bushing from housing and pressing new bushing into place.

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RE-ASSEMBLY

8. NOTE: DETERMINE MOUNTING CONFIGURATION OF WINCH (R.H. or L.H. MOUNTED)

BEFORE ATTACHING UPRIGHT FRAME TO WINCH, TO ASSURE PARTS ARE MOUNTED TO PROPER SIDE, REFER TO WINCH MOUNTING CONFIGURATIONS ON PAGE 12.

Seat well-oiled quad-ring #42 into groove of bushing in each end of drum assembly #1. Carefully

set drum assembly down over motor end bearing #9. Lift gear-housing end bearing #10 and set into place on drum assembly. Attach tie bars #2 and #3 using (8) capscrews #19 and lockwashers #25. Install (4) shoulder bolts #29 and hand tighten. Tighten (4) innermost capscrews securely; check rotation of cable drum. Tighten (4) outer-most capscrews securely, check rotation of cable drum. Torque capscrews, in above innermost then outer-most pattern, to 430 ft.-lbs. each. Torque shoulder bolts to 30 ft.-lbs. each. Check rotation of cable drum assembly. It must rotate freely with no tight spots.

OUTER-MOST

CAPSCREW

INNER-MOST

CAPSCREWS

OUTER-MOST

CAPSCREW

9. Place end (with longest splines) of output coupling assembly #6 through end bearing bushing #15

and mesh coupling spline with spline inside of drum. Slide clutch spacer #31 over end and against shoulder of shifter shaft #13. Place shifter shaft through washer #30 and into shaft coupling #7, meshing splines of shifter shaft with splines in shaft coupling.

LONGEST SPLINES

Page 12

10. Set gasket #37 into place on gear housing end bearing #10. Place ring gear #51 onto end bearing,

aligning holes in ring gear with holes in gasket and gear housing end bearing. Use (2) capscrews to temporarily secure ring gear to end bearing. Place (2) gear carrier assemblies into ring gear meshing carrier gears with ring gear. Slide input sun gear over shifter shaft #13 and mesh with teeth of input carrier. Apply grease to input thrust washer and place into slots of gearbox cover. Place gasket #37 into position on gearbox cover #4 with sealer. Remove (2) temporary capscrews and attach cover and gasket to ring gear end bearing. Use (12) capscrews #17 to secure gearbox to gear housing end bearing. Torque capscrews to 87 ft-lbs. each, in a criss-cross pattern.

11. Pull rod from air cylinder as far as possible. Slide washer #26 over setscrew #22 and against nut

attached to air cylinder rod. Place setscrew into hole of shifter shaft #13 and attach air cylinder to gearbox cover using (4) capscrews #24. Apply Loctite PST thread sealer to threads of capscrews. Torque capscrews to 5 ft-lbs. each, in criss-cross pattern.

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12. Gently tap key #11 into keyway of input shaft #12. Liberally apply grease to shoulder of input

shaft. Place 1-3/4 OD washer #28 over end of shaft and against shoulder of shaft. Place spring #46 inside of spring #47 and place both springs over shaft and against washer #28. Slide 2-3/8 OD clutch washer #30 over splined end of shaft and against springs. Use grease to hold springs and washers in place on shaft. Place splined end of shaft through drum and into output coupling #6. Mesh spline of input shaft with internal spline of coupling shaft inside of drum.

With pin #45 installed in coupling #8, align keyway of coupling with key on end of input shaft. Slide

coupling over end of shaft #12. Place gasket #36e into position on motor mounting surface of end bearing #9. Use (2) screws #20 to attach brake adapter plate #36d to motor end bearing. Torque capscrews to 85 ft-lbs. each. Place second gasket #36e on adapter plate. Insert brake shaft with key into coupling. Use (2) screws #18 to attach brake assembly to adapter plate. Torque capscrews to 97 ft-lbs. each.

Note: Care must be taken to assure cover and brake module are seated properly prior to installing

1/2-13NC assembly bolts. Damage will occur to rotor stack or shaft snap ring if not properly installed.

36c

36e

36d

36a

36e

13. Attach motor #41 with well-oiled gasket #36a to

brake #36. Use (2) capscrews #17 and torque to 74 ft.-lbs. each. Securely connect tube #48 to elbow #33, in top of valve #49, and fitting #34 in top of brake #36.

36a

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14. Apply Permatex to thread of plug #44. Thread plug into tapped hole in bottom of gear housing end bearing #10. Pour approximately 4.75 pints of SAE 80W-140 oil into end bearing. Check oil level by removing oil plug noted below. Insert relief fitting #39 and thread reducer #43 into end bearing at oil fill hole. Be sure breather vent #39 and relief fitting #43 are not damaged and in good operating condition. Replace if necessary.

Install winch and connect pressure lines. Apply at least 230 PSI pressure to release brake and verify that brake releases, by observing that the winch drum rotates.

15. Check proper operation of clutch by applying air pressure to clutch air cylinder to disengage clutch. Verify that winch freespools. Re-engage clutch. A loud noise should be heard when the clutch engages. Winch drum should not freespool.

16. Operate winch forward and reverse to verify that drum rotates.

OIL LEVEL PLUG

R. H. MOUNTING

CONFIGURATION

L. H. MOUNTING

CONFIGURATION

WINCH MOUNTING CONFIGURATIONS

Page 15

18.28

464,3

9.75

68,3

2.69

(TYP)

12.88

327,1

247,6

.50

12,7

(TYP)

2-PLACES

4.00 101,6

(TYP)

1/8-27NPT PORT

39,6

22° 30'

451,8

17.79

8.90 226,0

4.80 121,9

AIR PRESSURE TO TENSIONER

TAPERED SLEEVE FOR 1/4" DIAMETER TUBING.

(50 PSI MIN.)(100 PSI MAX.)

PNEUMATIC

PORT LOCATION

BRASS COMPRESSION FITTING

711,2

28.00

CABLE IN ROTATION

16.00

406,4

1/8-27NPT PRESSURE

PORT (100 TO 120 PSI)

FOR DISENGAGING CLUTCH.

(CLUTCH IS SPRING

ENGAGED.) SEE END

ORIENTATION OF PORT.

VIEW FOR TRUE

.96

24,3

.29

7,4

CABLE

ANCHOR

23,0

.906

484,8

19.09

41.62

1057,1

10.95

278,1

5.47 138,9

1.56

433,3

17.06 Ø

DRUM

FLANGE

7.00 177,8

DRUM

22.52

572,0

20.22

513,5

1/4" SPADE

12V FOR HIGH SPEED/LOW TORQUE MODE

20.43

518,9

STATIC LOAD

HOLDING BRAKE

2.41

61,1

2.89

73,4

7.95

7/8-14 SAE STRAIGHT

THREAD O-RING PORT

(2-PLACES OPPOSITE SIDES)

201,8

355,6

14.00

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

RPH-40000 2-SPEED (R.H. CONFIGURATION, "B" ROTATION SHOWN)

Page 16

LONGEST SPLINES

36e

36d

36e

36c

36a

RPH 40,000 WINCH

36b

Page 17

DESCRIPTION

PART

NO.

FITTING – HYD. 7/16-20 90° ELBOW

PARTS LIST – RPH 40,000

DESCRIPTION ITEM QTY.

PART

NO.

QTY.

ITEM

1 1 234191 DRUM ASSEMBLY 29 4 418453 SHOULDER BOLT

2 1 243047 TIE BAR 30 2 418460 CLUTCH WASHER

3 1 243048 TIE BAR 31 1 426044 SPACER – CLUTCH

4 1 328158 GEAR BOX COVER 32 1 426045 INSERT

5 1 299731 TENSIONER ASSEMBLY (SEE FOLLOWING PAGE) 33 1 432018

6 1 324295 COUPLING – OUTPUT 34 1 432023 FITTING – 7/16-20 STRAIGHT

7 1 324283 COUPLING – SHAFT 35 1 433017 AIR CYLINDER

8 1 324284 COUPLING – BRAKE 36 1 438037 BRAKE ASSEMBLY

9 1 338365 END BEARING – MOTOR a 1 BRAKE

10 1 338366 END BEARING – GEAR b 1 MOTOR END GASKET

11 1 342081 KEY – RD. END c 1 KEY

12 1 357522 SHAFT – INPUT d 1 ADAPTER PLATE

13 1 358064 SHAFT – SHIFTER e 2 ADAPTER PLATE GASKET

14 2 402117 BEARING 37 2 442210 GASKET – GEAR BOX

15 1 412086 BUSHING – THRUST 38 1 442217 GASKET – AIR CYLINDER

16 4 414400 CAPSCREW 3/8-24NF X 4 HX HD 39 1 456008 RELIEF FITTING

17 12 414557 CAPSCREW 1/2-13NC X 6 LG. HX HD GR 5 40 1 456038 BREATHER VENT

18 2 414595 CAPSCREW 1/2-13NC X 3 1/2 HX HD GR8 41 1 458101 MOTOR – HYDRAULIC

19 8 414784 CAPSCREW 7/8-9NC X 2 LG. HX HD GR 5 42 2 462040 QUAD. RING

20 2 414947 CAPSCREW 1/2-13 NC X 1LG. SOC HD 43 1 468004 REDUCER

21 2 414948 CAPSCREW 1/2-13NC X 1-1/4 SOC HD 44 1 468019 PIPE PLUG

22 1 416051 SETSCREW 5/16-24NF X 1 LG. SOC HD 45 1 470075 PIN

23 1 416072 SETSCREW 1/2-13NC X 3/4 LG. HX SOC HD 46 1 494120 SPRING – CLUTCH, INNER

24 4 416211 CAPSCREW #10-24 NC X 3.25 HX SOC HD 47 1 494114 SPRING – CLUTCH, OUTER

25 8 418261 LOCKWASHER 7/8 MED. SECT 48 1 509122 TUBE ASSEMBLY

26 1 418429 WASHER – THRUST 49 1 516035 VALVE – CONTROL ("B" ROTATION)

27 1 418430 NUT – 5/16-24NF X 1/8 THK, LOCK 516036 VALVE – CONTROL ("A" ROTATION)

28 1 418440 WASHER – SPRING, 1-3/4 OD 50 1 468040 PIPE PLUG

51 1 530123 GEAR BOX

Page 18

CABLE TENSIONER (OVERWOUND) - 299744

Item No. Part No. Quantity Description

1 265102 1 LEVER ARM 2 304174 1 BAR 3 346046 1 PIVOT PIN 4 408362 1 BRACKET 5 414278 4 CAPSCREW-3/8-16NCX3/4LG,HXHD,GR.5, ZINC PLATED 6 414316 2 CAPSCREW-3/8-16NCX1 1/4,HXHD,GR.5, ZINC PLATED 7 418045 2 NUT-3/8-16NC HEX REG GR.5, ZINC PLATED 8 418098 1 NUT-3/4-16NF HEX JAM

9 418177 2 LOCKWASHER-3/8 MED SECT,ZINC PLATED 10 418223 2 WASHER-1/2 USS FLAT,ZINC PLATED 11 424005 2 COTTER PIN 12 432033 1 FITTING-ELBOW 13 433029 1 ACTUATOR

Page 19

Page 20

LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY WINCH to be free from defects in material and workmanship for a period of one (1) year from date of purchase.

The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the Manufacturer's factory, or at a point designated by the Manufacturer, of such part that shall appear to the Manufacturer, upon inspection of such part, to have been defective in material or workmanship.

This warranty does not obligate RAMSEY WINCH to bear the cost of labor or transportation charges in connection with the replacement or repair of defective parts, nor shall it apply to a product upon which repair or alterations have been made, unless authorized by Manufacturer, or for equipment misused, neglected or which has not been installed correctly.

RAMSEY WINCH shall in no event be liable for special or consequential damages. RAMSEY WINCH makes no warranty in respect to accessories such as being subject to the warranties of their respective manufacturers.

RAMSEY WINCH, whose policy is one of continuous improvement, reserves the right to improve its products through changes in design or materials as it may deem desirable without being obligated to incorporate such changes in products of prior manufacture.

If field service at the request of the Buyer is rendered and the fault is found not to be with RAMSEY WINCH's product, the Buyer shall pay the time and expense to the field representative. Bills for service, labor or other expenses that have been incurred by the Buyer without approval or authorization by RAMSEY WINCH will not be accepted.

See warranty card for details.

RAMSEY WINCH COMPANY

Post Office Box 581510 Tulsa, Oklahoma 74158-1510

Telephone: (918) 438-2760 FAX: (918) 438-6688

OM-914188-0407-D